3A+G Technology & Turnkey Production Solutionxfsconnect.com/upload/files/Resources/3A+G Technology and Turnkey... · 3A+G TECHNOLOGY & TURNKEY PRODUCTION SOLUTION ... G GR-326-CORE

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3A+G Technology & Turnkey Production Solution

XFS COMMUNICATIONS, INC.

XFS COMMUNICATIONS, INC. 3A+G TECHNOLOGY & TURNKEY PRODUCTION SOLUTION

1 Influence of Connectors’ Attenuation on Fiber Network Performance

The larger the attenuation, the greater the decrease in power received, thus increasing the bit-error-rate (BER). A receiver discards damaged packets due to bit errors and asks for them to be retransmitted, thus adding to latency. Connectors with extremely low attenuation help to lower BER at the receiver and to reduce latency, thereby boosting network performance.

As the data rate continues to increase, the influence of the connectors’ attenuation on network performance will become more pronounced. Extremely low loss connectors are a future proof solution.

Extremely low insertion loss

+ high return loss = No.1 optical

performance

Zero scratches and defects on ENTIRE ferrule’s end-face

3D specs are stricter than IEC’s while polishing first-pass rate > 99%

Telcordia reliability test passed


2 “3A+G”: World’s No.1 Fiber Optic Connector

A-grade Optical PerformanceRandom mated insertion loss (SM)≤ 0.07dB (average)≤ 0.12dB (for 97% of samples)Return loss (APC) ≥ 70dBReturn loss (UPC) ≥ 55dB

A-grade End-face Quality100% of the entire ferrule end-faces of our fiber optic connectors are free of dirt, scratch and chipping

A-grade 3D GeometryRadius of curvature: 7 ≤ x ≤ 9 (APC)Apex offset (μm): 0 ≤ x ≤ 30Fiber height (nm): -30 ≤ x ≤ 30APC angle (°): 7.8 ≤ x ≤ 8.2Key error (°): -0.2 ≤ x ≤ 0.2

GR-326-CORE CertifiedPassed Telcordia GR-326-CORE testing conducted by Telcordia Network & Product Integrity (NPI) in Piscataway, NJ, USA

Fiber connectors are widely known as the weakest and most problematic points in a fiber network. XFS pro-poses “3A+G” as the perfor-mance and reliability level for our SM/MM patchcords, pigtails and pre-terminated cables with most connector types of SC, LC, FC, ST, MU, E2000, MT and MT-RJ.

A

A G

A



3A+G Connector’s Optical Performance (single-fiber connector)

Item Parameter Reference

Single mode Multimode

Insertion loss Random mated average ≤ 0.07dB; Random mated average ≤ 0.05dB; IEC 61300-3-34

Random mated for 97% ≤ 0.12dB Random mated for 97% ≤ 0.10dB

Return loss ≥ 70dB (APC); ≥ 45dB IEC 61300-3-6

≥ 55dB (UPC)

A A-GRADE OPTICAL PERFORMANCE "3A+G" connector has an average random mated insertion loss of just 0.05dB to 0.07dB, exceeding the performance level of IEC 61753-1 Grade B. Its power loss is merely 1.1% to 1.6%, or one-tenth of the industry average. "3A+G" manufacturing process is easy to operate and produce, delivers high yields, and uses ordinary materials to produce superb optical performance. It is a revolutionary production technology that produces the best quality for low costs.


A A-GRADE OPTICAL PERFORMANCE

MM Return Loss Distribution

MM Random Mated Insertion Loss Distribution


SM APC Random Mated Insertion Loss Distribution

SM APC Return Loss Distribution

0

50

100

150

200

250

300

350

0,25

0,24

0,23

0,22

0,21

0,2

0,19

0,18

0,17

0,16

0,15

0,14

0,13

0,12

0,11

0,1

0,09

0,08

0,07

0,06

0,05

0,04

0,03

0,02

0,01

0

50

100

150

200

250

300

350400

0,21

0,2

0,19

0,18

0,17

0,16

0,15

0,14

0,13

0,12

0,11

0,1

0,09

0,08

0,07

0,06

0,05

0,04

0,03

0,02

0,01

0

50

100

150

200

250

300

350

400

82,5

82,0

81,5

81,0

80,5

80,0

79,0

78,0

77,0

76,0

75,0

74,0

73,0

72,0

71,0

70,5

69686766656463626160

0

50

100

150

200

250

300

350

55,0

54,5

54,0

53,5

53,0

52,5

52,0

51,5

51,0

50,5

50,0

49,5

49,0

48,5

48,0

47,5

47,0

46,5

46,0

45,5

45,0

IEC 61753-1Grade B mean

IEC 61753-1 Grade 1

IEC 61753-1 Grade B max



A A-GRADE 3D GEOMETRY“3A+G” fiber optic connector has more rigorous end-face geometry than IEC: the radius of curvature, apex offset, fiber height and APC angle have all been effectively controlled for exceptional product consistency and optical performance. More importantly, despite such rigorous specifications, “3A+G” manufacturing process can still achieve a polishing first-pass yield of over 99%.

Radius of curvatureSC/APC

3A+G 7mm 9mm

IEC 61755-3-2 5mm 12mm

LC/APC

3A+G 7mm 9mm

IEC 61755-3-2 5mm 12mm

SC/UPC

3A+G 10mm 15mm

IEC 61755-3-1 5mm 30mm

LC/UPC

3A+G 9mm 12mm

IEC 61755-3-1 5mm 30mm



A A-GRADE 3D GEOMETRY

Fiber heightSC/APC, LC/APC, SC/UPC, LC/UPC

3A+G -30nm 30nm

IEC 61755-3-2 -100nm 100nm

APC angleSC/APC, LC/APC

3A+G 7.8° 8.2°

IEC 61755-3-2 7.5° 8.5°

Apex offsetSC/APC, LC/APC, SC/UPC, LC/UPC

3A+G 0μm 30μm

IEC 61755-3-2 0μm 70μm



End-face Examination Standard (SM)

Zone Range(μm)

XFS IEC 61300-3-35 ed2.0 (APC)

Scratches Defects Scratches Defects

A: Core 0 to 25 None None 4 ≤ 3μm None

B: Cladding 25 to 115 None None No limit

No limit < 2μm5 from 2μm

to 5μmNone > 5μm

C: Adhesive 115 to 135 None None No limit No limit

D: Contact 135 to 250 None None No limit None > 10μm

E: Rest of ferrule None None No limit No limit

A A-GRADE END-FACE QUALITY

For end-face quality, IEC guidelines allow a small number of defects that are small in size. “3A+G” fiber optic connector is the first in the industry to deliver connectors with zero defects on the entire ferrule end face. Thus the connector’s light-extraction efficiency is optimized, and its top-notch optical performance can hardly be matched by other manufacturers.

Zero defects in the Core, Cladding and Adhesive zones

The Contact zone and its edges are also free of defects



G GR-326-CORE CERTIFICATION BY TELCORDIA/ERICSSON

· Flammability Test

· Intermateability Test

· Optical Performance Test

· Thermal Age Test

· Thermal Cycle Test

· Humidity Aging Test

· Humidity/Condensation Cycling Test

· Post-Condensation Thermal Cycle Test

· Vibration Test

· Flex Test

· Twist Test

· Proof Test

· Transmission With Applied Tensile Load Test

· Impact Test

· Durability Test

· End of Test Criteria Test

· Dust Test

· Adhesive Testing

· Airborne Contaminants Test

· Salt Spray Test

· Immersion/Corrosion Test

· Groundwater Immersion Test

· Ferrule Endface Geometry Test

· Connector Installation Test

· Extended Thermal Age Test

· Extended Humidity Test

· Extended Thermal Cycle Test

Telcordia GR-326-CORE is one of the most rigorous reliability testing criteria in the industry. "3A+G” APC optical jumpers have passed the GR-326-CORE testings conducted by Telcordia's NPI division in New Jersey, USA.

XFS SC/APC 3.0mm Jumper

Testing Certificate

XFS SC/APC 0.9mm Jumper

Testing Certificate



M EXTREMELY LOW LOSS MPOS: THE BEST SOLUTION FOR DATACENTER INTERCONNECT

Endface Geometry (12c MPO Connector)

XFS IEC 61755-3-31:2015

Minus Coplanarity (nm) ≤200 ≤400

Ferrule Surface X-Angle (°) -0.075 to +0.075 -0.15 to +0.15

Ferrule Surface Y-Angle (°) 7.8 to 8.2 7.8 to 8.2

Fiber Height (nm) 1500 to 2500 1000 to 3500

Fiber Differential Height-All (nm) ≤200 Not defined

Fiber Differential Height-Adj. (nm) ≤150 ≤300

Fiber Tip Spherical Radius (mm) ≥1 ≥1

Ferrule Surface X-Radius (mm) ≥2000 ≥2000

Ferrule Surface Y-Radius (mm) ≥50 ≥5

Core Dip (nm; for MM) 0 to 100 Not defined

Geometry Limit ≤10 ≤17.4

MPO connectors are well-suited for high-density, high-traffic applications. XFS’ manufacturing process employs one of the most advanced polishing technologies for producing MPOs with the best optical performance in the industry.

“With XFS’ proprietary polishing technology, we can produce low-loss MPOs without using low-loss MT ferrules.”

Optical Performance (12c MPO Connector)

Item Parameter Reference

Single mode Multimode

Insertion loss

Typ. 0.1dB 0.05dB

IEC 61300-3-4

Max 0.25dB 0.15dB

Return loss APC: ≥65dB; UPC: ≥50dB ≥35dB IEC 61300-3-6


M EXTREMELY LOW LOSS MPOS: THE BEST SOLUTION FOR DATACENTER INTERCONNECT


XFS Standard SM MPO Insertion Loss Distribution

XFS Standard MM MPO Insertion Loss Distribution

XFS Standard MM MPO Return Loss Distribution

XFS Standard SM MPO Return Loss Distribution

0

30

60

90

120

150

0,35

0,33

0,31

0,29

0,27

0,25

0,23

0,21

0,19

0,17

0,15

0,13

0,11

0,09

0,07

0,05

0,03

0,01

0

50

100

150

200

72,75

72,25

71,75

71,25

70,75

70,1

69,6

69,1

68,6

68,1

67,6

67,1

66,6

66,1

65,6

65,1

0

50

100

150

200

250

0,34

0,32

0,30

0,28

0,26

0,24

0,22

0,20

0,18

0,16

0,14

0,12

0,11

0,09

0,07

0,05

0,03

0,01

0

50

100

150

200

250

5049,5

4948,5

4847,5

4746,5

4645,5

45,1

44,6

44,1

43,6

43,1

42,6

42,1

41,6

41,1

40,6

40,1

39,6

39,1

38,6

38,1

37,6

37,1

36,6

36,1

35,6

35,1

Telcordia GR-1435-COREUltra grande (max.)

Telcordia GR-1435-COREUltra grande (max.)

Telcordia GR-1435-COREUltra grande (min.)


Revolutionary Production Technology for Manufacturing Fiber Optic Connectors


12 3A+G Production Technology

PEOPLE

The production process is greatly simplified and drastically different from traditional ones. Operator training time is reduced from 30 to 7 days. Jigs are used for all

procedures for reducing human error and improving efficiency.

MACHINE

Innovative, self-developed equipment: High performance polishing

machine for realizing top quality optical termination with low cost.

Multi-functional inspection machine for efficient quality checking.

MATERIAL

Comprehensive material control: Unique material supply chain and production monitoring system for

effectively controlling material quality. 3A+G process uses only ordinary

materials for producing with the best performance.

SYSTEM

Process control system: Self-developed. First in the industry.

Using barcode management means the state of every work station is

known and immediate action can be taken, greatly boosting management

efficiency and improving yields.

"3A+G" production technology made systematic, scientific and revolutionary changes to the four main factors in manufacturing: people, machine, material and system. It is a complete manufacturing solution with self-developed processes, machines, tools, material management system and quality control system. "3A+G" production technology achieves what has never been achieved in the industry before: consistent mass production of A-Grade fiber optic connectors at a low cost.


13 3A+G Production Technology: PatentsPatent name: AN END-TO-END METHOD FOR MANUFACTURING FIBER OPTIC CONNECTORS WITH ZERO INSERTION LOSS AND HIGH RETURN LOSS

Type: invention patentApplicant: XFS Communications, Inc.Patent No.: 201610266527.8

This invention discloses a method for manufacturing fiber optic connectors with zero loss. The method includes trimming, pre-assembly, fiber fixing, back-assembly, adhesive removal and polishing treatment. The aforementioned polishing treatment uses independently controlled polishing jigs to perform the polishing procedure in a spiral manner. During the polishing process, the abrasive in progressively reduced in size. The aforementioned fiber optic connector product is affixed to the aforementioned polishing jig and polished on high-precision polishing machines to become the final fiber optic connector product. The manufacturing method of zero-loss fiber optic connectors in this invention possesses the following features: consistent quality, low quality risk, high production efficiency, excellent optical performance, low signal transmission lose, good overall performance and low cost.

Patent name: A POLISHING METHOD USED FOR MAKING FIBER OPTIC CONNECTORS WITH ZERO INSERTION LOSS AND HIGH RETURN LOSS

Type: invention patentApplicant: XFS Communications, Inc.Patent No.: 201610270137.8

This invention discloses a polishing method used for making lossless fiber optic connectors. The fiber optic connector uses independent controlled polishing jigs to perform a spiral polishing process. The polishing jig includes the jig body. The jig body features connector holding cavities parallel and independent of each other. All connector holding cavities have a connector mount at the base. Attached to the connector mount is a holding column for securing the fiber optic connector in place. At the top of the holding column is a uni-directional screw that is used to move the top of the connector holding cavity. A spring that can move up and down is set into the top of the connector holding column. During the polishing process, the abrasive is progressively reduced in size. The fiber optic connector product is affixed to the polishing jig and polished on the high-precision polishing machine. This polishing method for manufacturing zero-loss fiber optic connectors in this invention possesses the following features: excellent optimal performance, low signal transmission lose, good overall performance and low cost.

Patent name: HIGH-PRECISION INTELLIGENT POLISHING MACHINEType: utility model patentApplicant: XFS Communications, Inc.

Patent name: HIGH-EFFICIENT 3D GEOMETRY INTERFEROMETRIC TESTING METHOD & TOOLType: utility model patentApplicant: XFS Communications, Inc.

Patent name: INSERT LOSS AND END-FACE COMBINED INSPECTION MACHINEType: utility model patentApplicant: XFS Communications, Inc.

Patent name: LONGITUDINAL FIBER STRIPPING TOOLType: utility model patentApplicant: XFS Communications, Inc.


14 3A+G Production Technology: Competitive Advantages

A-grade product with optimized optical performance and reliability · Self-developed longitudinal heat stripping technology for eliminating fiber damage · Self-developed constant temperature curing technology for effectively blocking the impact of environment on adhesive and greatly increasing connector’s tensile strength · Self-developed intelligent polishing technology with fully digital control and high-precision polishing surface · Self-developed simplified 3D inspection technology for reducing testing time by 90%

Optimized SOPs for eliminating human error, realizing high yields and efficiency · All production process are carried out with jigs for simplifying manual operations and reducing human error · Multi-functional equipment are employed to greatly reduce production time · Factory zoning is applied to realize a flexible production, improving efficiency for both high-volume, low-mix and low-volume, high-mix production · Self-developed Process Control System for real-time monitoring, analyzing and controlling of production process to effectively improve yields and efficiency

Optimized low-cost manufacturing, realizing top-notch quality with competitive cost structure · A vertically integrated model is employed that most of the components, jigs, tools and equipments are made in-house · Multiple polishing procedures of short durations are employed for greatly reducing consumption of polishing films and pads · The compatibility issue between fiber and ferrule core is effectively addressed, in that ordinary ferrules and connector kits can be used for producing A-grade products · Innovative on-line cleaning procedure (OCP) effectively controls the cleanness of end face, in that a clean room is not needed for achieving 100% A-grade output

Turnkey production module optimized for fast deployment of manufacturing line and MP · 3A+G production technology is integrated into a modularized, end-to-end turnkey plant export solution including production line planning and establishment; design and manufacturing of jigs, tools and equipment; installation/testing/operation/maintenance of jigs, tools and equipment; personnel training; raw material and consumable selection; pilot to mass production and quality assurance; follow-up technical support


15 3A+G Production Technology: Self-developed Equipment & Tools

All production and testing jigs, tools and equipment were developed and fabricated in-house. They are easy to use, highly efficient, low-cost, and essential for producing world-class quality and reliability products.

Fiber damage inspector

· Check the for any damage caused during hot stripping

Small oven

· Low-power and steady heat

· Constant temperature cover to shield curing oven temperature from the external environment

SC inner frame assembly jig

· Light, fast with fool-proofing

LC inner frame assembly jig

· Light, fast with fool-proofing

Riveting machine

· Long moment arm with high pressure design

Automatic hot stripping machine

· Set the heating temperature and time based on the external cladding diameter and material

· Fixed-length hot stripping

Ferrule extrusion length inspector

· Monitor the extrusion length of ferrule and the result of glue removal process

High-precision intelligent polishing machine

· High-precision flat surface

· One polishing machine per polishing procedure to avoid parameter misconfiguration

· Implementation of one-button polishing

Online dehumidifier

· Fast online dehumidification to reduce end face contamination

Simplified 3D geometry interferometer

· Visual inspection-based geometric testing for accurate and speedy inspection

Insertion loss and end-face combined inspection machine

· One-stop inspection of end face and insertion loss to greatly reduce inspection time

Specialized polishing working table

· Constant temperature water supply system

· Wastewater filtration system


16 3A+G Production Technology: APC Polishing

Proprietary polishing process reinvents traditional polishing machine for intelligent, high-precision, “One-Button Operation” surface polishing.

The technology is based on independent polishing. The pressure is applied to each connector by an individual spring. The polishing path of each connector is separate with overlap so grime and powder does not cross over. The technology progressively reduces abrasive size over six polishing procedures: D30, D15, D9, D3, D1 and ADS. Each of the six polishing procedures last for not over 30 seconds. Multiple short polishing procedures allow timely removal of produced powder, improving polishing quality and extending polishing films’ re-use times.

POLISHING FILM USAGE PROCEDURE

POLISHING PATH ON A POLISHING FILM

D3020 secs

D1520 secs

D330 secs

D930 secs

D130 secs

ADS30 secs

Fully utilize the top, down, left, right side of polishing film

3A+G

3A+G


17 World's First Patchcord Factory Turnkey Production Solution

our office


18 Modularized Turnkey Production Solution

With over 30 years of experience of manufacturing fiber patchcords for the most prestigious customers in the industry, XFS now proudly introduces the world’s first patchcord factory turkey production solution for helping worldwide manufacturers establish the capability of producing the world-class quality patchcords with low capital expenditure and competitive product cost structure.

The turnkey solution includes: the end-to-end production line planning and establishment; design and manufacturing of equipment, fixtures and tools; installation/testing/operation/maintenance of equipment, fixtures and tools; personnel training; material and consumable selection; pilot production and quality assurance; and continued technical support.

The turnkey solution is based on one module producing 3500 ends of SC/APC (or 4500 ends of LC/APC) connections with 100% “3A+G” level over one 10-hour shift.

FACTORY ESTABLISHMENTOptimize factory layout, equipment placement and personnel allocation based on profit target

OPERATOR TRAININGUnique operator training system for minimizing human error while production

MATERIAL SUPPLYComprehensive material supply support system collaborating seamlessly with 3A+G manufacturing process

EQUIPMENT SUPPORTTurnkey plant export of equipment and tools; training on equipment operation; long-term maintenance service

PRODUCTION SUPPORTExperienced technical team is stationed on-site for solving production problems and ramping up yield and efficiency

CONTINUED UPGRADEXFS has continued to refine its manufacturing process over years. Improvements are exported to customers on a regular basis


19 Modularized Turnkey Production SolutionXFS ”MODULE”

· The standardized 3A+G production process for manufacturing fiber interconnect products including pigtails, patchcords, pre-terminated cables and MPO assemblies are combined into a module built around the 3A+G polishing process

· Each module has 6 polishing machines and needs a total of 10 operators

· The turnkey solution is based on one module producing 3500 ends of SC/APC (or 4500 ends of LC/APC) connections with 100% “3A+G” level over one 10-hour shift.

· Self-developed equipment and tools with simplified SOPs are employed for minimizing investment cost, maximizing production efficiency and achieving the best quality

http://v.youku.com/v_show/id_XMTYxODg0ODYxMg==.html

CABLE CUTTING

· High-precision, high-efficiency automated equipment

· Fuzzy color identification of length for efficiency and convenience

· Standard operating process

CONNECTOR KITS ASSEMBLY

· Fixed longitudinal stripping for consistent length

· Stripping jig for high efficiency

· Easy-to-use visual alignment method

FIBER CURING

· Fiber stripping machine can be set for fixed time and temperature for high efficiency without fiber damage

· Small oven insulated from ambient temperature for stable curing

BACK-END ASSEMBLY

· Inner and external assembly frames for efficiency, convenience and error proofing

· Long moment arm with high pressure riveting press for steady pressure and good results

GLUE REMOVAL

· Quick and effective removal of cured glue on front end of the core

· Easy to use, more effective and much cheaper than conventional laser cleaver for glue removal

FERRULE’S EXTRUSION LENGTH MEASUREMENT

· CCD visual inspection

· Set up different polishing groups based on ferrule’s length to ensure consistent polishing pressure and height

POLISHING

· Multiple short polishing procedures improve polishing and increase first-pass rate

· Next-generation high-precision polishing machine for even more stable polishing

· Simple 3D geometry and end face inspectors to significantly improve QA efficiency

PACKAGING

· Sort into cartons and package in order for high efficiency

FIXTURE CENTER

· Constant cleaning and maintenance of polishing fixtures to ensure high level of consistency in polishing quality

· Polishing fixtures’ dimensions and spring pressure are under constant monitoring

GLUE ROOM

· Store glue at constant temperature and humidity to ensure consistent quality

· Thorough mixing of AB glue by precisely controlled ratio


Product performance (IL, RL, 3D, end face quality) is the best in the world

Product reliability has GR-326-CORE certification by Telcordia/Ericsson

High yield; 3D geometry polishing first-pass rate > 99%

Production process is simple, stable and efficient, thus less operators are needed and skilled workers are not needed, greatly reducing labor costs

Ordinary ferrules, connector kits and consumables are sufficient for producing A-grade products, greatly reducing material costs

All equipment and tools are self-developed, greatly reducing the investment in fixed assets

“3A+G” production process is a revolutionary technology that can consistently produce high-quality products at low cost. Our turnkey solution can give patchcord manufacturers a quantum leap in technological advancement in a short amount of time!


”For the past 30 years, we focus only on making the best optical termination in the world.”— Charles Sun, CEO, XFS

TAIWAN OFFICE:

5F-1, No.2, Ln.57, Chongyang Rd., Taipei 11573, Taiwan

CHINA FACTORY:

Bldg.B, No.9 Jiejiabao Rd., Shiyan, Baoan District, Shenzhen 518108, China

[email protected]

+86-755-2675-5668

xfsconnect.com

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3A+G Technology & Turnkey Production Solutionxfsconnect.com/upload/files/Resources/3A+G Technology and Turnkey... · 3A+G TECHNOLOGY & TURNKEY PRODUCTION SOLUTION ... G GR-326-CORE